GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Sunfire 🢒 Engine 🢒 Engine Cooling 🢒 Heater Core Replacement

Removal Procedure

    Object Number: 604145 Size: SH
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
  2. Remove the heater core case cover screws and cover.
  3. Remove the heater core bracket screws and brackets.
  4. Remove the heater core from the HVAC module assembly.

Installation Procedure

    Object Number: 604145 Size: SH
  1. Install the heater core to the HVAC module assembly.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the heater core brackets and bracket screws.

    3. Tighten
    Tighten the bracket screws to 1 N·m (9 lb in).

  3. Install the heater core case cover.
  4. Install the heater core case cover screws.

    5. Tighten
    Tighten the cover screws to 1 N·m (9 lb in).

  5. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .